Method of making electromagnetic induction apparatus



' Dec. 22, 1942.

J. .J. VIENNEAU METHOD OF MAKING ELECTROMAGNETIC INDUCTION APPARATUS Original Filed Feb. '14, 1940 4 Sheets-$heet l Dec. 22, 1942. VIENNEAU 2,305,650

METHOD OF MAKING ELECTROMAGNETIC INDUCTION APPARATUS originalFiled Feb. 14, 1940 4 Sheets-Sheet 2 Fig. 5.

Inventor: Jacob J. Vienneau,

His Abtorngg.

Dw J. J. VIENNEAU 2,305,650

METHOD OF MAKING ELECTROMAGNETIC INDUCTION APPARATUS 4 Sheets-Sheet 5 Original Filed Feb." 14, 1940 Inventor. Jacob J. Vienneau, J WETJWZAM His Abbornqg.

Dec. 22, 1942. J. J. vlENNEAeJ I METHOD OF MAKING ELECTROMAGNETIC INDUCTION APPARIEJTUS Original Filed Feb. 14 3.940 4 Shaetsfihaet 4 Li ff Patented Dec. 22, 1942 METHOD OF MAKING ELECTROMAGNETIC INDUCTION APPARATUS Jacob J. Vienneau, Pittsfield, Mass, assignor to General Electric Company, a corporation of New York Original application February 14, 1940, Serial No.

318,868. Divided and this application September 9, 1940, Serial No. 356,094

13 Claims,

This application is a division of my copending application, Serial No. 318,868, filed February 14, 1940, for Electromagnetic induction apparatus and method of making the same.

My invention relates to electromagnetic induction apparatus and more particularly to transformers, reactors, and the like with strip-wound magnetic circuits, and methods of making such apparatus.

The current carrying or conductive winding elements of transformers and the like are generally more reliable and otherwise more advantageous when they are preformed and pretreated to improve their insulation before they are assembled with the magnetic circuit or core, as in the case of form-wound coils. Letters Patent to John C. Granfield, No. 2,160,588, May 30, 1939, for Electromagnetic induction apparatus and method of making the same, assigned to the assignee of the present application, discloses and claims such apparatus wherein the magnetic members are composed of strip-wound magnetic material which has been heat treated and then operatively linked with such form-wound conductive windings without a permanent alteration in the physical state or magnetic properties developed by the heat treatment. The Granfield construction and method are applicable to a fairly wide range of transformer sizes and are particularly applicable to distribution transformers of small and moderate sizes, which sizes of transformers can be very advantageously and efficiently designed with magnetic cores in the form of substantially circular cylinders and with conductive windings having winding legs of a cross sectional shape adapted to be operatively linked with such circular cylindrical cores with a high space factor.

In some applications and particularly in the larger distribution transformers and in power transformers, such circular cylindrical shapes constitute a handicap to the designer in securing economically the favorable values of reactance or heat dissipation or insulation safety or other characteristic of conventional transformers of the same ratings with laminated cores built up of punchings. Such conventional transformers in the larger sizes, especially those of the socalled concentric type generally preferred for the higher voltages, have their axial sections rectangular with the length of the longer sides several times that of the shorter sides. These shapes and proportions have been developed in the art with long experience in securing certain desirable transformer performance and reliability, combined with economy. In accordance with my invention for the first time, so far as I am aware, these advantageous features and characteristics can be secured while also securing the great advantage of the wound core arrangement since, in my construction and method of operation, non-circular wound cores are operatively linked with winding legs of an elongated or oblong axial section and closely embrace or fit the winding legs so as to provide a high space factor.

It is a general object of my invention to produce transformers and the like having formwound conductive winding assemblies with leg cross-sections of an elongated or polygonal shape with any ratio between the lengths of adjacent sides, and having also a strip-wound magnetic core of a non-circular cylindrical shape operatively to link and surround said winding leg with high space factor.

Another object of my invention is to produce transformers of the class described above which will be more eflicient than those possible heretofore for the same weight of materials.

If it is attempted to produce transformers of the type described by winding up a core from strip in the shape desired, then heat treating, unwinding, and rewinding it around the conductive winding assembly in accordance with the art developed for circular cores, it will be found that a very slight creepage of the turns of the core beyond or behind (generally behind in non-circular cores) their'normal positions, too small to be of any consequence in circular cores, may, by

accumulation of such displacement from turn to i turn, soon cause the curves, corners and straight portions of later turns to get so far out of alignment with corresponding portions of earlier turns, that the rewinding of the core into its original heat treated form becomes impossible.

It is a principal object of my invention to provide constructional principles and methods which will avoid such difficulties whereby wound heat treated cores having practically any. non-circular shape of window can be unwound and rewound into their original forms with great convenience and without resort to excessive force and conse' quent injury to the insulation of the windings and impairment of magnetic properties of the cores.

One of the important principles of my invention is based on the prevention of accumulation of small unavoidable displacements between successive turns to intolerable misalignments in the characteristics-3.3 course of the winding b providing at frequent intervals a small space between adjacent turns, for a small portion of the turn, sufficient to accommodate those small unavoidable inaccuracies which tend to cause creepage of a turn beyond or behind its normal position.

These and other principles, objects and advantages of my invention will be apparent from the following description and claims, and my invention will be more readily understood from such description when considered in connection with the accompanying drawings; and those features of the invention which are believed to be novel and patentable will be pointed out in the claims appended hereto. In the drawings, Fig. 1 is a plan view of a wound-strip core after anneal and ready to be applied to a conductive-winding structure. Fig. 2 is a plan view of a transformer winding structure and of the core material shown in the initial stage of the process of application to the transformer winding structure, the latter being shown partially in section and broken away in part. Fig. 3 is a view corresponding to Fig. 2 but illustrating another more advanced stepin the process of applying the core strip to the conductive winding. Figs. 4 to 7, inclusive, are similar views showing still more advanced successive steps in the process, the outer turns of strip of the larger loop of strip being omitted in Figs. 4 to '7 to simplifythe drawings. Fig. 8 is an elevation of the completely assembled transformer illustrated in the foregoing figures. Fig. 9 is a plan view partially in section of a modified design of stationary induction apparatus. Fig. 10 is a schematic diagram showing a step in the process of assembling the design of Fig. 9. Fig. 11 is a diagram illustrating a step in a modified process. Fig. 12 is a plan view of a modified core with the conductive winding shown in section. Fig. 13 is a diagram illustrating one step in a modified method of assembly for producing cores, such as illustrated in Fig. 12 and Fig. 14 is a diagram illustrating another embodiment of my invention. Fig. 15 is a lan view partially in section of a modified embodiment of my invention in which the winding legs are curved instead of straight, and Fig. 16 is an elevation of the construction represented in Fig. 15. Like reference characters are utilized throughout the drawings to designate like parts.

The apparatus I have illustrated involves certain modifications of the specific constructions illustrated in the aforesaid Letters Patent to Granfleld No. 2,160,588, but is designed to obtain the various advantages of the Graniield construction and method of assembly such as low losses, magnetizing current, weight and cost, ability to use low-loss magnetic material such as high reduction cold rolled 3% silicon steel strip, e. g., with the magnetic flux flowing lengthwise, i. e., in the direction of the most favorable magnetic properties of the strip, use of formwound fully insulated conductive-winding structures, application of the cores to the winding structures in such a manner as to avoid strains above and below the elastic limit, and so forth as discussed more in detail in the Graniield patent.

For the purpose of making the heating in the conductive windings smaller than would be the case in a conductive-winding structure having a substantially circular cross-section I utilize a conductive-winding structure of non-circular cross-section such as square, elongated, rectangular, oval, elliptical or the like as this increases the area of cooling surface of the conductive aaoacso winding exposed to cooling medium such as air or oil for a given cross-sectional area and weight of conductor material. In Figs. 2 to 8 I have represented a transformer having a conductivewinding structure ii including the requisite in sulation and a magnetic core consisting of a. pair of core parts or separate wound cores i2, each wound on a side or leg l3 of the winding structure, the winding leg I! preferably being straight for the sake of high space factor.

In the following description I shall make reference to transformers by way of illustration, but it will be understood that the invention is applicable as well to reactors. Although the conductive-winding structure II, that is, the winding legs i3 may have a practically rectangular crosssection, that is, either square or oblong, as illustrated by the section [4 in Fig. 9, in the arrangement of Figs. 1 to 8 I have shown a winding-leg section which, in effect, has the corners rounded off, or the cross-section may be regarded as elongated with rounded ends and straight sides.

The conductive winding structure I I being for a transformer, of necessity includes primary and secondary windings. It. may, for example, consist of a single high tension winding IS with a pair of low tension windings I6 which, it will be understood, may be connected in series to form an electrically continuous winding. Although in Fig. 8 I have shown a winding structure having two winding legs and including three windings, it will be understood that my invention is not limited to this specific arrangement but obviously includes winding structures comprising one or more windings and having a different number of winding legs than two, for example, such as in the winding structure described in Patent No. 2,221,687 which was granted after the filing of my present application upon the copending application of Sidley 0. Evans for Transformer assembling method and apparatus, Serial No. 292,173, filed August 28, 1939, and assigned to the same assignee as the present application in which there is a plurality of conductive windings radiating from a core axis with a side of each winding passing through the core to form a winding leg common to all the conductive windings. By making the windings I6 slightly shorter in cross-section than the winding l5, the shape of the ends of the winding leg section becomes roughly round so as to permit the use of the core l2, having an opening or window IT, the ends of which are rounded so as to simplify the process of shaping the core material by avoiding sharp bends therein. It will be understood that, although for simplicity in the drawings the winding structure II is shown as consisting of three apparently mechanically independent windings, in actual practice the windings comprising the winding structure II are securely fastened together and may, if desired, have an outer wrapping of insulating tape around all of the windings. It will be apparent that elongated coils or windings forming the winding structure H may be braced more easily than would be the case if they were shortened so as to produce substantially circular cross-section. The methods of bracing and securing the winding structure are not a part of my invention and are not peculiar to my construction and may be approximately the same as in transformers having elongatedsection conductive windings, but using cores built up of stacked laminations.

In addition to the usual bracing in such conductive winding structure, however, my construcbe done before the core is applied to the insulated tion has additional mechanical strength and rigidity resulting from the fact that the cores |2 closely embrace the conductive-winding legs IS. The winding structure II also tends to hold together the cores i2. Furthermore, the construction is highly economical of both copper for the conductive winding, and iron for the core. The space factor is high, the core window being substantially filled by the winding leg l3, and the window i8 of the conductive-winding structure being substantially filled by the material of the cores l2 (see Fig. 8). Moreover my construction has the advantage of permitting better control of electrical characteristics than ordinary circular-cross-section conductive windings.

The cooling surface of the winding structure I3 is relatively great with respect to its cross-sectional area as the length of the cross-section is about one and one-half times the width of the cross-section. The exact ratio of length to width may, of course, be varied in various designs. In the case of large transformers the high and low tension windings may be spaced, providing channels therebetween for the passage of insulating and cooling fluid. The elongated section of the conductive winding structure also decreases the reactances of the transformer windings l5 and I6 since it increases the length of the flux leakage paths l9, thus increasing their reluctance. Examining Fig. 2, for example, it will be seen that the leakage paths IQ for the low potential windings l6 are relatively long since the flux traverses twice the cross-sectional length of the windings.

This gives the transformer lower reactance and results in better regulation. The relatively large heat dissipating surface, of course, gives the transformer good thermal characteristics. The use of a core free from strains above and below the elastic limit and composed of a suitable low loss material, such as high-reduction-cold rolled 3% silicon strip results in low losses, low magnetizing current, and low cost and weight for a given output as compared with a transformer having a core built up with stacked laminations.

To avoid the relatively poor space factor of an elongated-section winding structure with respect to the circumscribed circle, I do not use a wound core having a true circular opening or window, but use a core having an elongated window fitting the winding leg. In order that the core with its elongated window may be applied to the conductive winding structure without straining the magnetic material beyond the elastic limit, certain precautions must be taken. In forming the larger loop mentioned in the Granfield Patent No. 2,160,588 for the purpose of threading the strip through the window of the conductive winding structure, the portions of strip of approximately the same length and curvature in successive layers of the larger loop are lined up, as represented in Figure 3, and furthermore, in order to avoid binding in collapsing the larger loop to the finished core, the cores are so made that there is a slight degree of looseness or spacing between layers of strip material at the ends or at the corners of the core; but the layers at the long sides are in close contact providing a large contact-surface area, thereby avoiding any interference with the passage of magnetic flux between layers of strip.

In order to obtain the favorable magnetic properties of low-loss magnetic strip having the flux flowing in the direction of the length of the stripv the strip must be arranged in the exact shape and size which the turns of material are to have in the finished core. Heat treatment must, of course,

conductive winding structure. Accordingly, the strip material is first wound upon an arbor 20 having the shape and size which the core window i1 is to have in the finished apparatus, the core window I! conforming to the outline of the crosssection of the winding leg |3 which includes the insulation of the conductive windings, whereby the core window iits the winding structure and high space factor of the conductive winding material is obtained. In this manner there is built up a coil of magnet strip 2|, as shown in Fig. 1. The magnetic strip is wound in such a manner that there is spacing between the turns at one or both of the ends 22 or at the corners 23, or both at the ends 22 and the corners 23. This may be done in any suitable manner such as rotating the arbor 20 about its center 24 as an axis while holding the strip of magnetic material being fed to the arbor perpendicular to the axis and winding in suitable spacing material, or rotating the arbor and deflecting the strip to and fro transversely to the axis of the arbor to rufile up the strip and introduce spacing crinkles or flutings at the ends 22 or the comers 23 as the strip is deflected back to prevent it from running off the edges of the mandrel axially and forming a conical helix. After the magnetic coil is wound in this latter manner, and before it is annealed, the edges of the various layers of strip may be forced into alignment, and the coil supported with pressure on the sides to cause the spaces to remain at the ends.

Preferably I cause the strip to wind on to the mandrel smoothly by keeping the strip perpendicular to the arbor axis and I provide the spacing by introducing shims 25 between the layers of strip at ends or short sides 22 or at the corners 23, but my invention is not limited thereto and does not exclude using as spacing material continuous strip having a sufficiently low melting point to run out during the heat treatment or loose powder,

The shims 25 may be relatively thin and inserted at each end between adjacent layers of strip. This exact spacing arrangement need not be employed, however, for I have found, for example, as shown in Fig. 1, that satisfactory results may be obtained by separating each pair of layers by a shim from the adjacent pairs of layers of strip, and employing shims 25 of the same thickness as the strip of magnetic material. The shims 25 may in fact be short strips of the same material. I may arrange matters in such a manner that the pair of layers of strip which is close together at one end of the coil 2| is separated by shims at the other end of the coil 2|. Although there is spacing between the continuous strip material at the ends and corners 22 and 23, it will be apparent that the successive layers of strip are in close contact all along the sides 26 of the coil 2|. To minimize the possibility of strain in heavy cores it is advantageous to make the cores with the turns spaced at one end only. In this case the weight of the core and coils together may rest and be supported on the end of the core that has no space between turns.

After the coil 2| of the form shown in Fig. 1 has been suitably heat treated to bring out its desirable magnetic properties and to give it a permanent set, the material having cooled, the strip maybe applied to the conductive winding structure. The outer layers of coil 2| are unwound passing the end 21 of the strip through the winding window I8 (Fig. 2 and bringing it .mit surrounding the winding leg back upon the next adjacent lower layer of strip 28 to form a larger loop 29, surrounding both the winding leg l3 and the original coil of strip 2|. It will be advantageous to secure the end 27 of the strip to the next lower layer of strip in some suitable manner as by means of spot welding. The larger loop 29 and the coil of strip 2| are rotated so as to pass more and more of the material through the conductive winding window it], transferring it from the outside of the coil 2| to the inside of the larger loop 29. The formation of the larger loop permits transference of the material without exceeding the elastic limit of the material or producing any permanent deleterious effects upon its properties' Throughout the assembling process care is taken to avoid excessive bending or jarring of the strip.

In forming the first turn of the larger loop 29 and fastening its end 21, it is not enough merely to make the loop sufficiently large to enclose the core and winding leg with ease. It is a principle of the present invention that each turn of the loop includes a whole number of sides of the original turns and a whole number of ends or curved portions of the original turns, in

order that successive turns of the larger loop can be formed so as to line up long straight sides of original turns with each other and the curved portions of the original turns with each other in the successive turns of that larger loop. For example, as seen in Fig. 3, portions of relatively short length and short radius of curvature, such as the portions 30, are lined up along one another, and substantially straight portions 3| are also lined up along one another. It will be observed that the curved portions 30 are those portions of the strip which were originally at the ends 22 of the coil 2| of Figs. 1 and 2, and that the portions 3| which are very nearly straight or have a slight opposite curvature from that of 30 are those portions which were formerly at the straight sides 28 of the original coil 2|. The larger loop 29 should be of sufficient size to peri3 and the original coil 2| without crowding, while the unwinding and simultaneously rewinding operation is going on. Likewise the difference in size between the original coil 2| and the larger loop 29 should also be sufficiently great so that when all of the material has been transferred to the larger loop 29, there will be few enough layers of strip in the winding window |8 so that they can'be passed through one-half the winding window without binding upon the conductive winding, assuming that the construction is one in which there are two separate cores I2. for with one of the cores l2 already in place there would, of course, be only one-half winding window available for the larger loop 29. Lining up the adjacent layers of strip portions 30 and 3| of similar length and radiu of curvature respectively permits making the portion of the loop 29 within the winding window 18 sufficiently compact for passing through the winding window. Although niy invention is not limited to making the larger loops 29 of the specific size shown in relation to the original coil 2|, I have found it satisfactory to make the length of the strip in each turn of the larger loop 29 three times that in each turn of the original coil 2|, thus forming a six-sided or hexagonal figure in which each "angle is one of the short-radius curved portions 30.

After all of the strip material has been trans ferred to the larger loop 29, the inner end 32 of the strip is released and permitted to wrap itself around the winding leg I3. If the strip was wound around the arbor 20 with the inner end 32 coming at the middle of one of the long sides of the window l1, and the end 32 is released when the larger loop is in the position shown in Fig. 3. the strip wraps itself about halfway around the winding leg as shown in Fig. 3. Owing to the permanent set of the strip material the inner end of the larger loop 29 tends to hold itself against the winding leg i3. However. if desired. the end 32 may be secured to the winding structure l3 in any suitable manner. The next step in the process is collapsing the larger loop 29 upon the winding leg i3. However, all turns of the larger loop 29 are not collapsed simultaneously, but instead, the loops are collapsed successively beginning with the inside loop. The strip is manipulated with sufiicient gentleness to avoid stretching or bending any part of it beyond the elastic limit. The manner in which the strip is arranged in the loops makes the proper manipulation a relatively easy matter.

During the collapsing process, all of the turns of the larger loop 29, with the exception of the turn which is the inner turn at the time, for example, turn 33 in Fig. 3, are held together and are rotated together as a unit: and the forward portion 33' of the inner turn 33 is allowed to slip about the initial one-half turn 34 which is already wrapped around the. winding leg |3, to permit the backward portion 33 of turn 33 to wrap itself around 34. It will be evident that in so doing the inner turn 33 will be shortened, and whereas its original length was three times the length of the turn in the original coil 2|, that s to say. the layer 33 actually consisted of three layers of the original coil 2|, the length will be reduced successively to various smaller whole number of times the length of a half-turn of the original loop 2|. In the illustrative example shown, the inner layer 33 of the hexagonal" loop 29 has six angles or short-radius curved portions 30. However, after one of these angles" has been slipped by the winding leg l3, the inner layer 33 of the larger loop 29 will consist of only five sides and angles" and the length of the layer 33 will be only two and one-half times the length of a layer or. turn in the original coil 2|, as represented by the pentagonal inner turn 35, in Fig. 4, in which only the inner turns of the larger loop are shown for simplicity. The turn 35 contains a whole number of times the length of the material in a half turn of the original coil 25. that is. five times. It will be understood that in Figs. 4-7, inclusive, the outer portions of the larger loop 29 have been omitted for the sake of avoiding unnecessary confusion in the drawings.

After the larger loop 29 has been rotated surficiently to cause another part or side of the polygonal inner layer 33 to slip by the inner half turn 34 on the winding leg I3, the former inner layer 33 would have only four angles, as represented at 36 in Fig. 5. and its length would be reduced to four times one-half an original turn. As shown in Fig. 6, the next step is the reduction of the inner layer 33 to a length 31 containing three angles, and three times the length of one-half turn in the original coil. As shown in Fig. '7, after one more angle" of the former inner turn 33 has been slipped around the inner half turn 34 of the final core, the inner layer 33 will have disappeared as such, and a portion of it will have become an additional small turn 38 surrounding the initial half turn 34 on the winding leg l3.

More accurately speaking, a portion of the inner layer 33 of Fig. 3 becomes the inner layer 35 of Fig. 4, and the rest of it corresponding to distance between angles becomes a portion 35' of the next layer of the larger loop 29. In a similar manner, a portion of the inner layer 35 becomes the smaller inner layer 36 of Fig. 5, with the portion 35 formerly in the layer 35 being left over to form a portion of the next layer of the larger loop 29. Likewise, a portion of the inner layer 36 becomes the inner layer 31 of-Fig. 6 with a portion left over, and a portion of the inner layer 31 becomes the smaller turn 38 of Fig. '7, whereas a portion 38', left over, becomes a part of a new inner layer 39.

After the first portion of the former inner layer 33 of the larger loop 29 of Fig. 3 has become the small turn 38 of Fig. 7 and the remainder with additional material from the next layer of the larger loop 29 has become a new inner layer 39, as shown in Fig. 7, the procedure represented by Figs. 3 to 7 is repeated. The rotation of the larger loop 29 is continued with all layers of the larger loop held together except the new inner layer 39, which is allowed to slip around the small turns 34 and 38 of the winding leg l3, in the same manner as described in connection with the inner layer 33 in Fig. 3. In this manner additional turns are wrapped about the winding leg l3 by successively collapsing only the inner layer of the larger loop 25 until all of the layers of the larger loop have been collapsed and all of the material of the larger loop has been reduced to its original size and shape to form the finished core l2, as illustrated in Fig. 8.

It will be apparent that as the material of the original coil 2| (Fig. 2) is unwound and rewound into the larger loop 29, the shims 25 will fall out and the finished cores 12 will be identical with the original coil 2|, shown in Fig. 1, with the exception that there are no shims therein. The finished cores l2 have straight sides 26, such as the original coil or strip 2|, and the layers pf strip will be in close contact at, and all along the sides 26. Consequently, the core l2 produces a continuous path for magnetic flux with the fiux gradually passing from one layer of strip to the next through contact surfaces of large cross-sectional area at the straight sides 26 of the core. Preferably the outer end 21 of the strip, indicated at Fig. 1, is fastened down to the next adjacent strip in the finished cores i2 in some suitable manner as by spot welding.

The cores l2 have thus far been described as each being composed of a single continuous strip of magnetic material, but of course a core may comprise one or more separate core elements, each made up of a continuous strip and arranged end to end or one around the other on the same winding leg.

Although in the foregoing figures and in the explanation, I have shown and referred to the magnetic core as having a window" with rounded ends, it will be understood that my invention is not limited thereto, and if there is a conductive winding structure 49 such as shown in Fig. 9 with an oblong section M, the process may be carried out in a similar manner as before by use of shims placed at the short sides or ends or placed at the corners of the original coil of strip so as to leave spaces 4i, to avoid binding in the rewinding and collapsing operations. The turns of the larger loop formed when applying an elongated linked with the winding structure.

rectangular hollow cylindrical core, such as that of Fig. 9, will be similar in shape to those shown in Figs. 2 to '1, inclusive, with the exception that the curved portions 30 of Fig. 3 will be replaced by pairs of angles 45 and short, relatively straight, portions 46 (Fig. 10) corresponding to the corners 42 and the short sides or ends 43 respectively of the core of Fig. 9. The long sides 44 of the core in Fig. 9 correspond to the con cave portions 44' in Fig, 10. Each of said pairs of angles will correspond to the angles or curved portions of short radius of curvature referred to in the explanation involving Figs. 3 to 7, inclusive. Similarly, with a conductive winding structure of square cross-section the larger loops would have angles" corresponding in number to the number of corners 42, equally spaced and separated by relatively straight portions corresponding to shorter sides or ends 43 and sides 44 of the original coil of strip of the unfinished core. In carrying out my process, the corners 42 open partially and the straight sides 44 become partially concave to form the larger loop without exceeding the elastic limit of the material. In the case of such square cross-section conductive windings, the lengths of turns in the larger loop might, of course, be a whole number of times one-fourth the length of a turn of the original coil of strip without interfering with alignment of the portions of approximately equal curvature in adjacent turns of the larger loop. Portions of strip of similar shape and size are repeated four times in each turn of the original coil of strip in the case of the aforesaid cores for square cross-section windings. Likewise portions of strip of similar size and shape are repeated twice in each turn of the original coil of strip used in the elongated constructions illustrated in Figs. 1 and 9, e. g. Such similar re peated fourths and halves of a turn of the original coil of strip may be referred to as aliquot fractions of a turn of the original coil of strip.

In forming the larger loop, each turn of the larger loop must contain a whole number of times such an aliquot fraction of a turn of the original coil of strip in order that the portions of strip of approximately equal curvature in adjacent turns of the larger loop will be in alignment. In using the term aliquot fraction, I means to include also unity or a single turn, for in the case of a D-shaped original coil of strip, e. g., each turn of the larger loop will need to contain a whole number of turns of the original coil of strip.

In connection with Figs, 2 to '7, I have described in detail a method of applying a core to a conductive winding structure which involves unwinding a heat treated coil of strip 2i and simultaneously rewinding it into a larger loop 29 linking the conductive winding structure. If the process is to be carried out by machine it may be more convenient first to rewind the strip into an intermediate loop of greater size than the core but less size than the larger loop which will be For example I may rewind the coil 2i into a threeor foursided figure such as the loop 41 indicated schematically' in Fig. 11, where each turn of the loop 41 is represented as containing four halfturns of the coil 2|. After the intermediate loop 41 is formed it may be held to its size by a mandrel which is free to rotate and rewound into a larger loop linking the conductive winding structure as previously explained in connection with the transformation of the coil 2| into the larger loop loop is collapsed upon the conductive winding leg in the manner previously explained, the mandrel having been removed.

While magnetic core elements as heretofore.

described consisting of a considerable number of turns of continuous strip can be assembled on the conductive windings, either manually or by machine, the assembly by hand may be carried out more easily and quickly where the magnetic cores are composed of a relatively large number or core elements or sections, each core element surrounding the preceding core element and each consisting of a small number of turns. With relatively few turns oi. continuous strip material in each core element, the operation of assembly may be performed quickly and easily manually by a single-operator. This construction will be described in connection with Figs. 12, 13 and 14.

A strip of material is first wound to form a coil of strip in which the successive turns of strip have the shape and size which they are to have in the finished core, as already explained in connection with the cores shown in Figs. 1 and 9. The requisitespacings between turnsflmay be provided by. means shims at both ends, as shown atFig. 1, or by means of shims at only one end in order to have the spacingsat only one end, as illustrated in Fig. 12. The strip so wound is then subjected to suitableheat treatment to bring out its desirable magnetic properties and relieve the material of strains, causing it to acquire a permanent set and tending to retain the turns of strip in the shape in which they were heat, treated. The coil of strip is then opened up or unwound to form a larger loop a few times the peripheral size oi the original coil of strip, as-discussed in connection with Figs. 11 and 2,- th strip not being wound into the winding structure, however, as shown in Fig. 2. The actual relationship between the length of the turns of strip in the coil of Fig. 12 and the perimeter of the loop may be selected at any one of several values, for example, with the perimeter of the larger loop twice, 2 times, 3 times, 3 times, etc., as large as the original coil of strip. In Fig. 13 is illustrated the larger loop formed by unwinding the coil 5i into what I call a tour-sided figure, that is, with the perimeter of the loop 52 twice as great as the perimeter of a turn of strip in the coil 5!. This is referred to as a tour-sided figure for the reason that it hasiour relatively long sides 53 corresponding to the long sides II of the turns in the coil of strip 5|.

The successive large turns in the larger loop are then cut out beginning at the inside. For example, first a cut is. made at the point 5' separating the inner large turn El. This large turn E1 is applied to the winding leg by opening up the large turn suiiiciently to admit the winding leg, whereupon the end 32 is laid against the winding leg l3, as in Fig. 3, after which the permanent set of the material causes the rest of the large turn, iii to wrap itself around the winding leg, as illustrated by the portion of the strip 34-38 in Fig. I. in this case, however, the core element applied consists of only two turns, because the large turn 5? consists of the two inner turns oi the original coil of strip which was oi. the same size as the finished coil ii. The same operation is then repeated, another cut being made at II to permit the next two turns of core element to be removed irom the larger loop I: and applied to the conductivewinding leg around the core element which has just been applied. These operations are carried out until all of the strip material has been applied to the conductive winding leg to iorm a finished core, such as the core H oi Fig. 12 linking the conductive winding and consisting of a plurality of core elements each composed of two turns of continuous magnetic strip material.

Ii the locations of the successive cuts 58, 58,

etc., are slightly staggered it will be apparent that the breaks I, '0, ii, etc., between the successive two-turn core elements will also be staggered. However, even without such staggering, good magnetic conditions can be obtained in the finished apparatus for the reason that the bridging of a break by an adjacent unbroken portion of strip in close contact with the ends of strip terminating at the break results in low-reluctance magnetic paths, from one core element to the next. It will be observed that the successive core elements are so applied that the strip ends formed by the cuts IS, I, etc., in Fig. 13 are in abutment in the finished core ll forming the breaks II, I, I, etc., as shown in Fig. 12. It is not necessary to make the cuts ll, 58', etc. accurately at any particular portion oi the strip, nor is it necessary that the cuts should be made exactly square or at any particular angle. Regardless of the position 0: angle at which the cuts 'are made the strip ends fit each other and form a close butt Joint in the finished core H. I! desired, a suitable stripsevering punch may be employed which produces a triangular, irregular or even dove-tailed shaped cut so as to produce interlocking between the adjacent strip ends. Burrs should be avoided at the out edges and, while the cutting or shearing operation will strain the metal at the edges of the cuts somewhat, the total losses due to these strains will be relatively small if the operation is carefully performed since these edges represent such a small fraction of the total iron in the core.

An alternative procedure in preparing the heat-treated coil of strip for assembling around the conductive winding leg in relatively shorter lengths, is to unwind the heat-treated coil of strip starting with its outside turn and cut pieces of desired length successively as the unwinding progresses. These pieces or lengths may be nested together, if economy of working space is desired while these core elements are being out. When the last core element or length of strip is made ready, it is assembled around the winding leg, and the rest of the core elements are assembled in their proper sequence around the winding leg restoring them to their original sire, shape and relative position in the heattreated coil.

had in the annealed coil. Consequently the turns of strip in the assembledinduction apparatus are in the same relative position as in the coil when annealed. They have their original size and shape and are substantially strain free, not being distorted even by the thickness oi! a layer of strip, which has been found to be of great importance in obtaininglow magnetic loss es. Thus high permeability and low watt-loss characteristics of the'cores can be obtained.

Although ahigher space factor within the core window can be obtained, especially in the case of cores wound from wide strips, by using conductive winding structures having straight winding legs than by using circular window conductive windings having curved winding legs, it will be understood that my invention is not limited to using straight winding legs. In the construction illustrated in Fig. the winding structure 66 has a circular window I8 for receiving the core and the core section is 'made cruciiorm'or with a stepped outline'for the sake of preserving a relatively high space factor within the window of the winding structure. The winding structure 66 has an annular projection on a plane perpendicular to its axis. However, the longitudinal sections cut by planes through its axis are rectangular, as in the caseof the arrangement'ot Fig.9. The core is divided into a number of parts with interfitting cross-section in order to increase the space factor. In the arrangement illustrated there are four radially-extending angularly-spaced core parts 61, i8, 69 and 10 each of. which includes core elements of diflerent width. The part 81 consists of a relatively wide co're'division' H and a narrower core division 12, each of which may comprise a continuous strip of magnetic mate rial forming a single core element, or may consist of a plurality of strips forming separate core elements, each core elenient surrounding the preceding element, such as the core elements'described in connection with the'preceding figures. The core division II is surrounded by the narrower core division 12 and if desired the strip of the core division 12 may be continuous with the strip in the core division "l i.

The core part 88 likewise is composed oi a. relatively wide core division 13 surrounded by 1' narrower core division 14'. The core parts Bi and S9 are similar, and-core parts 5% and is are 7 also similar with the relative widths and depths of the core divisions soselected that the cross sections of the four core parts 68 to E0 fit one another and produce a stepped outline filling most oi. the space within the conductivewinding window i8.

I have herein shown and particularly described certain embodiment of my invention and can tain methods of operation embraced therein for the purpose of explaining its principle and show ing its application but it will be obvious to those skilled in the art that many modifications and variations are possible and I aim, therefore, to cover all such modifications and variationsas tall within the scope of my invention which is defined in the appended claims.

What I claim as new and desire to secure by Letters Patent of the United States is:

' l. A method of applying a wound strip mag netic core to a winding leg of a conductive wind ing structure having an elongated cross-section, said, method comprising the steps of spirally winding magnetic material in strip form flatwise tightly upon an arbor having a cross-section corresponding to that of the winding leg in order to form .a coil of strip in which the turns have the same size, shape and relative positions they are to have in the magnetic core 01' the finally assembled apparatus, a plurality of shims having, however, been placed in the coil of strip thus built up at the end of the coil by inserting the shims successively under the strip as it is wound upon the underlying layers of strip, heat treating the coiled strip to give it a permanent set, unwinding the strip from theheautreated coil and simultaneously rewinding it into a larger loop without said shims around the leg oi the conductive winding structure, said larger loop being of sufilcient size to surround both the winding leg and the original coil without crowding and having in each turn a whole number of times the length of a half turn of the previously wound coil of strip, then causing the inner end of the larger loop to wrap itself about the winding legto form the beginning of a turn of the same size and shape as the inner turn of the wrapped aboutthe winding leg and thus original coil or strip, rotating the larger loop and causin'gthe inner turn thereof to slip around the strip end wrapped about the winding leg while causing the remaining turns of the larger loop to remain in the larger loop, thus decreasing the length of strip in said inner turn successively to smaller and smaller whole numbers of times the length of a half-turn of the previously wound coil or strip and correspondingly increasing the length of strip closely wrapped about the winding leg in the original size and shape of turn until all of the inner turn of the larger loop is closely appears as an inner turn of the larger loop, and thereafter repeating the procedure. with the portions of the strip which successively become the inner turn of the larger loop until all 01 the strip has been rewound substantially to the size and shape in which it was heat treated and thus closely embraces the winding leg.

2. A method oi applying a wound-strip magnetic core to a winding leg of a conductive winding structure-hating a noncircular cross-section, said method comprising the steps oi spirally winding magnetic material in strip form flatwlse into a non-circular coil of strip in which the turns have the same size and shape and relative positions as they are to have in the magnetic core 0! the finally assembled apparatus, heat treating the coiled strip to give it a permanent set, unwind- 7 ber of-times arr-aliquot traction of a turn at the original coil of strip and having in each turn portions or dinerent radius of curvature owing the lack of c cularity or the original coil of strip,

and the successive layers of material in the loop being so disposed that portions oi subset-an tially the same radius oi curvature aligned with one another in the successive layers, then causing the inner end of the larger loop to wrap itself about the winding leg to form the beginning of a turn of the same size and shape as the inner turn of the original coil of strip, rotat ing the larger loop and causing the inner turn thereof to slip around the strip end wrapped about the winding leg, decreasing the length of strip in said inner turn successively to smaller and smaller whole numbers of times the aliquot fraction of a turn of the original coil of strip and correspondingly increasing the length of strip closely wrapped about the winding leg in the original size and shape of turn until all of the inner turn of the larger loop is closely Wrapped about the winding leg and thus disappears as an inner turn of the larger loop, and thereafter repeating the procedure with the portions of the strip which successively become the inner turn of the larger loop until all of the strip has been rewound to the size and shape in Which it was heat treated.

3. A method of applying a magnetic core in the form of a coil of strip to a winding leg of a conductive winding structure having a non-circular cross section, the core having a window substantially corresponding in shape to the cross-section of the winding structure, and the material thereof having a permanent set, said method comprising the steps of unwinding the strip from the original coil of strip and simultaneously rewindeach turn of strip having portions of different radii of curvature owing to the non-circularity of I, the coil of strip, said method comprising the steps of unwinding the strip from the original coil of strip, winding into a larger loop, linking the larger loop'fw'ith the conductive winding structure, said Is: rloop being of sufficient size to surround both t ,e 'winding leg of the winding structure and the'orlginal coil without crowding, having in each j'turn a whole number of times an aliquot fractiofgbfa turn of the original coil of strip, portions or successive layers of the larger loop having corresponding radius of curvature being put in alignment as the larger loop is size and shape of the original coil of strip.

ing it into a larger loop around the leg of the conductive winding structure, said larger loop being of sufficient size to surround both the winding leg and the original coil without crowding, having in each turn a whole number of times an aliquot fraction of a turn of the original coil of strip and having in each turn portions of difierent radius of curvature owing to the non-circularity of the original coil of strip, and the portions of corresponding radius of curvature in the successive layers of the larger loop being in alignment, then causing the inner end of the larger loop to wrap itself about the winding leg to form the beginning of a turn of the same size and shape as the inner turn of the original coil oi strip, rotating the larger loop and causing the inner turn thereof to slip around the strip end wrapped about the winding leg, decreasing the length of strip in said inner turn successively to smaller and smaller whole numbers of times the aliquot fraction of a turn of the original coil of strip and correspondingly increasing the length of material closely wrapped about the winding leg in the original size and shape of turn until all of the inner turn of the larger loop is closely wrapped about the winding leg and thus disappears as an inner turn of the larger loop, and thereafter repeating the procedure with the portions of the strip which successively become the inner turn of the larger loop until all of the strip has been rewound to the size and shape of the original coil of strip.

4. A method of applying a magnetic core in the form of a fiatwise spirally wound coil of strip to a winding leg of a conductive-winding structure having a non-circular cross-section, the core having a window substantially corresponding in shape to the cross-section of the Winding structure, and the material thereof having a permanent set with a substantial length of each turn of strip in the coil in close surface contact with the adjacent turns, and a major number of turns having a portion of the periphery of the turn spaced from an adjacent turn of strip material,

5. A method. of applying a magnetic core in the form of a non-circular fiatwise spirally wound coil of strip to a winding leg of a conductivewinding structure. the material of said core having a permanent set with a substantial length of each turn of strip in the coil in close surface contact with the adjacent turns, and a major number of the turns each having a portion of the periphery of the turn spaced from an adjacent turn of strip material, each turn of strip having portions of difierent radii of curvature owing to the non-circularity of the coil of strip, said method comprising the steps of unwinding the strip from the original coil of strip and simultaneously rewinding it into an intermediate loop, said intermediate loop being of larger size than the original coil of strip, having in each turn a whole number of times an aliquot fraction of a turn of the original coil of strip, portions of the successive layers of the intermediate loop having a corresponding radius of curvature being put in alignment as the intermediate loop is being formed, then unwinding the intermediate loop and simultaneously rewinding it into a larger loop around the leg of the conductive winding structure, saidilarger loop being of sufficient size to surround both the winding leg and the intermediate loop without crowding, also having in each turn a whole number of times an aliquot fraction of a turn of the original coil of strip, portions of successive layers of the larger loop having corresponding radius of curvature again being put in alignment as the larger loop is formed, then collapsing the layers of the larger loop successively upon the winding leg of the conductive winding structure, beginning with the inner layer of the larger loop, to form a core of the size and shape of the original coil of strip.

6. A method of applying a wound-trip magnetic core having a non-circular window to a winding leg of a conductive-winding structure, said method comprising the steps of spirally winding magnetic material in strip form flatwise into a coil of strip in which the turns have the same size and shape as they are to have in the magnetic core of the finally assembled apparatus, spacing the turns of strip from one another at some portion of the periphery of the turns of the (3011 during the winding process and maintaining a substantial length of each turn closely in surface contact with the adjacent turns, heattreating the coil of strip to give it a permanent set, unwinding the strip from the original coil of rztr p and rewinding into a larger loop, linking the larger loop with the conductive Winding structure, and collapsing the larger loop upon s,sos,oso

winding leg of a conductive-winding structure,

said method comprising the steps of spirally winding magnetic material in strip form flatwise into a coil or strip in which the turns have the same size and shape as they are to have in the magnetic core of the finally assembled apparatus, spacing the turns of strip from one another at some portion or the periphery of the turns at the coil during the winding process and maintaining a substantial length oi each turn closely in surface contact with the adjacent turns, giving the turns oi! strip a permanent set, unwinding the strip from the original coil of strip and rewinding it into a larger loop, cutting the successive larger turns the larger loop apart to form a plurality of core elements, each'consisting of a plurality of turns of continuous magnetic strip, applying each 0! said larger turns in succession to the winding leg oi the conductive winding structure by wrapping the strip material in said larger turns around the winding leg to reduce of low space factor with respect to its circumscibed circle, the steps of producing a relatively large loop or strip consisting of large turns, each having a permanent set tending to cause said core to adopt a shape and size conforming to the shape and size of the cross-section or the winding leg 01 the conductive winding structure with high space iactor and having portions of different radii o! curvature in order to enable the core to conform to thenon-circular shape or the winding leg cross-section, portions of corresponding radii of curvature in successive turns of strip in the large loop being put in alignment, linking the turns of the larger loop with the conductive winding structure, successively reducing each oithe larger turns in size by causing it to wrapitselr about the winding leg to form smaller turns, each embracing the preceding turn.

9. The method of applying a wound strip magnetic core having a non-circular window to a winding leg of a conductive winding structure.

said method comprising the steps 0! spirally winding magnetic material in strip Iorm flatwise into a coil of strip in which the turns have the same size and shape as they are to have in the strip a permanent set, unwinding the strip from a I the original coil of strip, cutting the strip into sections oi different length, applying each of said sections, beginning at the inner end oi the original coil of strip, in succession to the winding leg 01 the conductive winding structure by caus- .ing the strip material to wrap around the windsection to abut the outer end oi! the strip in the preceding section thus restoring the core sections to the relative positions which they had in the original treated coil oi. strip with the cuts stasgered to minimize exciting current and with the turns of strip having substantially the same size and shape as originally and being free from strain.

10. The method conductive-winding structure having a non-cirsteps of spirally winding magnetic material in strip iorm flatwise into a coil of strip around an arbor having substantially the same cross-section as the winding leg of the conductive-winding structure to whichthe core is to be applied, each turn of strip having portions or difierent radii or, curvature owing to thenon-circularity of the arbor, maintaining a substantial length or each turn closely in surface contact with the adjacent turns, treating the material to give the turns at strip a permanent set, separating the turns of the original coil of strip without injury to their magnetic properties, putting portions of corresponding radius of curvature in successive turnsductive winding structure, causing the strip material to wrap around the winding leg and restoring the-turns oi strip to the relative positlons which they had in the original treated coil or strip with the turns of strip having the same size and shape as originally and with the material free from strains.

11. Themethod of assembling with a formwound conductive winding structure having a winding leg of non-circular cross-section, a flatwise spirally wound coil or substantially strainfree magnetic strip material having a substantial length of each turn of strip in the coil closely in surface contact with the adjacent turns and having a permanent set, each turn of strip having portions or diil'erent radii oi curvature owing to the non-circularity or the coil, said method comprising the steps of separating the turns in the original coil oi! strip without 1 to their end of the strip, to the winding leg of the conductive winding structure, causing the strip material to wrap itself around the winding leg, thus restoring the turns or strip to the relative posit iqns which they had in the original coil of strip with the turns of strip having'the same size and shape as originally and with the material being substantially free from strain deleterious to its magnetic properties. I I

12. The method of applying a wound strip magnetic core having a non-circular window to a winding leg or a conductive winding structure, said method comprising the steps of spirally winding magnetic material in strip form flatwise into a coil of strip in which the turns have the same size and shape as they are to have in the magnetic core of the finally assembled apparatus, maintaining a substantial length of each turn closely in surface contact with the adiacent turns. tmting the material to give the turns or strip. a permanent set, unwinding the strip from as original coil oi strip, cutting the ing leg, causing the inner end-oi the strip in each strip into sections with code so shaped as to be or applying a wound-strip magnetic core to a winding leg of a form-wound adapted for interlocking with the abutting ends of other sections, applying each of said sections,

beginning at the inner end of the original coil 01 strip, in succession to the winding leg oi the conductive winding structure by causing the strip material to wrap around the winding leg, causing the inner end oi! the strip in each section to interlock the outer end of the strip in the preceding section thus restoring the core sections to the relative positions which they had in the original treated coil of strip with the turns of strip having substantially the same size and shape as originally and being free from strain.

, 13. The method 01' applying a wound strip I magnetic core to a winding leg or a form-wound conductive-winding structure having a non-circular cross-section, said method comprising the steps of spirally winding magnetic material in strip form flatwise. into a coil of strip around an arbor having substantially the same cross-section as the winding leg of the conductive winding structure to which the core is to be applied, spacing turns of strip at some portion 01 the periphery of the turns of the coil during the winding process and maintaining a substantial length of each turn closely in surface contact with the adjacent turns, giving the turns of strip a permanent set, separating the turns of the ori inal coil of strip without injury to their magnetic properties. and applying portions of the coil of strip successively, beginning at the inner end, to the winding leg of the conductive winding structure with the turns of strip in the relative positions which they had in the original treated coil of strip, with the turns oi strip having the same size and shape as originally and with the material being free from strains.

.mcon J. vmmmo. 

